Sensor module and robot cleaner having the same

ABSTRACT

A sensor module and a robot cleaner including the sensor module may provide accurate sensing of an obstacle and prevent an erroneous sensing of an obstacle. The robot cleaner may include a body including a cleaning unit to remove foreign substances from a surface of a floor, a cover to cover an upper portion of the body, a sensor module including an obstacle sensor mounted to sense an obstacle, and a sensor window provided at one side of the sensor module. The sensor module may include a light emitting device to emit light through the sensor window, a light receiving reflector on which light reflected from the obstacle is incident, and a light shielding portion interposed between the light emitting device and the light receiving reflector to block the light emitted from the light emitting device from being incident upon the light receiving reflector.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the priority benefit of Korean PatentApplication No. 10-2013-0039847, filed on Apr. 11, 2013 in the KoreanIntellectual Property Office, the disclosure of which is incorporatedherein by reference.

BACKGROUND

1. Field

Embodiments disclosed herein relate to a sensor module which is providedwith a sensor to sense an obstacle and prevent the sensor fromerroneously sensing an obstacle, and a robot cleaner having the same.

2. Description of the Related Art

A robot cleaner refers to an apparatus which autonomously travels aboutan area to be cleaned without user manipulation to perform cleaning bysuctioning in foreign substances such as dust on the surface of a floor.The robot cleaner determines, through an obstacle sensing sensor, adistance to an obstacle such as furniture, office supplies and wallsarranged in an area to be cleaned, and cleans the area, changing thetravel direction by selectively driving a left wheel motor and a rightwheel motor.

The obstacle sensing sensor of the robot cleaner may be an opticalsensor. The obstacle sensing sensor may include a light emitting unit toemit light and a light receiving unit to receive light emitted from thelight emitting unit and reflected from an obstacle. According to lightreflected from the obstacle transmitted to the light receiving unit, thedistance to the obstacle may be measured.

A housing forming the external appearance of the robot cleaner may beprovided with a transparent sensor window. Light emitted from the lightemitting unit may be transmitted to the outside through the sensorwindow. At this time, the light emitted from the light emitting unit maynot be transmitted to the outside, but may be reflected from the innersurface of the sensor window and be incident on the light receivingunit. In the case that the light reflected from the sensor window isincident on the light receiving unit, the robot cleaner may erroneouslyact as if there is an obstacle in front thereof, thereby failing toaccurately perform sensing of an obstacle.

SUMMARY

Therefore, it is an aspect of the present invention to provide a sensormodule which may provide accurate sensing of an obstacle by preventingerroneously sensing irrelevant light as if an obstacle is in front of arobot cleaner when light emitted from a light emitting unit is reflectedfrom the inner surface of the sensor window sensor module and a robotcleaner having the same.

Additional aspects of the invention will be set forth in part in thedescription which follows and, in part, will be apparent from thedescription, or may be learned by practice of the invention.

In accordance with an aspect of the present invention, a robot cleanerincludes a body including a cleaning unit to remove foreign substancesfrom a surface of a floor and a wheel unit to rotate via powertransmitted thereto from a motor, a cover to cover an upper portion ofthe body, a sensor module including an obstacle sensor mounted to thebody to sense an obstacle, and a sensor window provided at one side ofthe sensor module, wherein the sensor module includes a light emittingdevice to emit light outside through the sensor window, a lightreceiving reflector on which light emitted from the light emittingdevice and reflected from the obstacle is incident, and a lightshielding portion interposed between the light emitting device and thelight receiving reflector to block the light emitted from the lightemitting device from being reflected from an inner surface of the sensorwindow and incident upon the light receiving reflector.

The sensor module may include a base frame and an upper frame coupled tothe base frame.

A slit may be formed at one side of a front of the upper frame, and thelight shielding portion may be an upper surface of the upper frameforming the slit.

The light emitting device may be mounted to the base frame to correspondto a position of the slit, and the light emitted from the light emittingdevice may radiate forward through the slit.

A step portion may be formed on a front upper surface of the upper frameto prevent failure to sense a close obstacle. That is, the step portionmay enable the robot cleaner to sense objects or obstacles at arelatively closer distance.

The light receiving reflector may be mounted to the upper frame.

The upper frame may be provided with a mount protruding upward, and thelight receiving reflector may be mounted to an upper side of the mount.

The upper frame may be provided with a hole at a position correspondingto a lower portion of the mount.

The base frame may be provided with a light receiving unit camera toreceive information about the reflected light incident upon the lightreceiving reflector, the light receiving unit camera being arranged toface the light receiving reflector.

A docking sensor to transmit a signal to or receive a signal from thedocking station may be mounted to the mount.

The docking sensor may be positioned at an upper portion of the lightreceiving reflector.

A bracket to space the docking sensor from the light receiving reflectormay be interposed between the docking sensor and the light receivingreflector.

The base frame may be provided with a remote control signal receptionportion to receive a signal from a remote control.

The sensor module may be modularized as one unit by mounting the lightemitting device to the base frame, mounting the light receivingreflector to the upper frame, and coupling the base frame to the upperframe, and the sensor module may be mounted to a front of the body.

The sensor window may be integrated with the sensor module.

In accordance with another aspect of the present invention, a sensormodule includes a base frame, a plurality of light emitting devicesmounted to the base frame, a light shielding portion positioned at anupper portion of each of the light emitting devices, a light receivingreflector provided at an upper portion of the light shielding portion,and a light receiving unit camera mounted to the base frame to receive,at a lower portion of the light receiving reflector, an image relevantto light incident upon the light receiving reflector, wherein the baseframe, the light emitting devices, the light shielding portion, thelight receiving reflector, and the light receiving unit camera areintegrated with each other.

A slit may be formed at one side of the light shielding portion, and acorresponding one of the light emitting devices may be provided at aposition corresponding to the slit, such that light emitted from thelight emitting device is radiated outside through the slit.

The sensor module may further include a sensor window coupled to thebase frame or the light shielding portion.

The base frame, the light shielding portion and the sensor window may beintegrated with each other.

A step portion may be formed on a front upper surface of the lightshielding portion.

In accordance with another aspect of the present invention, a sensormodule may include a base frame, a light emitting device mounted to thebase frame to emit light through a sensor window toward an object; alight receiving unit camera to receive light emitted from the lightemitting device and reflected from the obstacle, and a light shieldingportion positioned above the light emitting device to prevent lightemitted from the light emitting device and reflected from an innersurface of the sensor window from being received by the light receivingcamera. The sensor module may further include a light receivingreflector to receive light emitted from the light emitting device andreflected from the obstacle, and to reflect the light emitted from thelight emitting device and reflected from the obstacle to the lightreceiving unit camera.

The light shielding portion may include an upper frame disposed abovethe base frame and the light emitting device, and a bottom surface ofthe upper frame may prevent light emitted from the light emitting deviceand reflected from the inner surface of the sensor window from beingreceived by the light receiving camera.

The sensor module may further include a mount disposed on an uppersurface of the upper frame, and the light receiving unit camera may bearranged on the mount to receive light emitted from the light emittingdevice and reflected from the obstacle directly. An end portion of theupper frame adjacent to the inner surface of the sensor window may stepdown at an incline toward the inner surface of the sensor window.

BRIEF DESCRIPTION OF THE DRAWINGS

These and/or other aspects of the invention will become apparent andmore readily appreciated from the following description of theembodiments, taken in conjunction with the accompanying drawings ofwhich:

FIG. 1 is a perspective view showing a robot cleaner according to anexemplary embodiment of the present invention;

FIG. 2 is a view showing the robot cleaner of FIG. 1, with a cover ofthe robot cleaner removed;

FIG. 3 is an exploded view showing a sensor module of the robot cleanerof FIG. 1;

FIG. 4 is an exploded perspective view showing the sensor module of FIG.3;

FIG. 5 is a view schematically illustrating sensing of an obstacle bythe sensor module of FIG. 3;

FIG. 6 is a view partially showing a sensor module according to anembodiment of the present invention;

FIG. 7 is a cross-sectional view showing the sensor module of FIG. 6;

FIG. 8 is a view schematically illustrating sensing of an obstacle bythe sensor module of FIG. 6; and

FIG. 9 is a view showing a sensor module according to an embodiment ofthe present invention.

DETAILED DESCRIPTION

Reference will now be made in detail to the embodiments of the presentinvention, examples of which are illustrated in the accompanyingdrawings, wherein like reference numerals refer to like elementsthroughout.

Hereinafter, a sensor module according to an embodiment of the presentinvention and a robot cleaner having the same will be described indetail with reference to the drawings.

FIG. 1 is a perspective view showing a robot cleaner according to anexemplary embodiment of the present invention, FIG. 2 is a view showingthe robot cleaner of FIG. 1, with a cover of the robot cleaner removed,and FIG. 3 is an exploded view showing a sensor module of the robotcleaner of FIG. 1.

Referring to FIGS. 1 to 3, the robot cleaner 1 includes a cover 10 and abody 20. The cover 10 may cover the upper part of the body 20.

The body 20 may include a cleaning unit to remove foreign substancesfrom the surface of a floor, a wheel unit to allow the robot cleaner 1to travel, and a motor to supply power to the wheel unit. The wheel unitmay include at least one wheel. The wheel rotates when power istransmitted thereto from the motor, thereby allowing the robot cleaner 1to travel. The wheel unit and the motor may be referred to as a drivingunit.

The robot cleaner 1 may include an electric power unit to supplyelectric power for driving. The electric power unit may include abattery electrically connected to each driving device adapted to drive acorresponding component mounted to the body 20 to supply power thereto.The battery may be a rechargeable secondary battery. The battery may berecharged by electric power supplied thereto from a docking station (notshown) when the body 20 is coupled to the docking station. The robotcleaner 1 may return to the docking station after completion ofcleaning, for example. The robot cleaner 1 may be coupled to the dockingstation before performing a cleaning process, or during the cleaningprocess, also. For example, the robot cleaner 1 may be coupled to thedocking station when a battery status is determined to be low, forexample lower than a predetermined level, or when it is necessary ordesired to empty a dust collector of the robot cleaner 1, as explainedbelow. When the dust collector is being emptied, the battery of therobot cleaner 1 may be charged, for example.

The robot cleaner 1 may include at least one wheel to receive drivingpower from the electric power unit to rotate. For example, two wheelsmay be symmetrically disposed at the left and right edges of a centralarea of the lower portion of the body 20. Wheels allow the robot cleaner1 to perform movement such as forward movement, backward movement, andturning while traveling. Due to operation of the wheels, the robotcleaner 1 may clean the surface of a floor. However, the disclosure isnot limited to a robot cleaner 1 having two wheels. For example, therobot cleaner 1 may have one wheel, or three or more wheels.

A caster may be further installed at the front lower edge of the body 20with respect to the travel direction. As the caster is provided, therobot cleaner 1 may be stabilized while traveling.

The robot cleaner 1 may include a cleaning unit. The cleaning unit mayinclude a brush unit arranged at the side of a suction port formed atthe lower side of the body. An inflow inlet connected to a dustcollector may be formed at the lower portion of the body 20. Dustaccumulated on the surface of a floor may be guided to the suction portwhen the brush unit rotates.

An air blower to generate suction force to suction in dust may beprovided in the body 20 of the robot cleaner 1. The air blower mayinclude a suction motor and a fan. The dust guided to the suction portmay be caused to move to the dust collector by the air blower.

Once a certain amount of dust is collected in the dust collector in therobot cleaner, the robot cleaner 1 may move to and dock with the dockingstation. Alternatively, the dust collector may manually be emptied by auser, for example. Once the robot cleaner 1 docks with the dockingstation, the dust collected in the dust collector in the robot cleaner 1may be suctioned into the dust collector in the docking station. Thedust collected in the dust collector in the robot cleaner 1 and/or inthe docking station may be disposed of by a user by separating the dustcollector from the robot cleaner/docking station. Thereby, the dustcollector of the robot cleaner 1 may be emptied manually by a user, orvia the dust collector of the docking station.

A dust amount sensor may be provided in the body 20 to sense the amountof dust in the dust collector. When it is sensed by the dust amountsensor that dust has been collected in the dust collector to an amountequal to or greater than a reference amount, a controller may drive thewheels to allow the robot cleaner 1 to move and dock with the dockingstation. After the robot cleaner 1 docks with the docking station, thedust collected in the dust collector in the robot cleaner 1 may besuctioned into the dust collector provided in the docking station.

A sensor module 30 may be mounted to one side of the body 20. The sensormodule 30 may include an obstacle sensor. The obstacle sensor may sensean obstacle positioned in front of the robot cleaner 1, for example.When it is sensed by the obstacle sensor that an obstacle is present infront of the robot cleaner 1, the controller may turn the body 2 of therobot cleaner 1 to change the direction of travel of the robot cleaner1. Thereby, the robot cleaner 1 may continue traveling in order toperform a cleaning operation, while also avoiding the obstacle.

When the presence of an obstacle in front of the robot cleaner 1 withrespect to the travel direction of the robot cleaner 1 is sensed, therobot cleaner 1 may turn in place to change the travel direction.Accordingly, a certain portion of the robot cleaner 1 faces forward inthe travel direction. Therefore, the sensor module 30 or the obstaclesensor may be mounted to the certain portion of the robot cleaner 1facing forward. The certain position at which the sensor module 30 ismounted may be defined as the front of the robot cleaner 1. Sensormodules may however be disposed at other locations of the robot cleaner1, if desired, and may be used to detect the proximity to obstacles indirections other than a direction in which the robot is traveling.

A sensor window 11 may be mounted to the front of the body 20. Thesensor window 11 may be formed of a material allowing light emitted fromthe obstacle sensor to be transmitted therethrough. The light emitted bythe obstacle sensor may be transmitted to the outside through the sensorwindow 11. As shown in FIG. 3, for example, the robot cleaner 1 may besubstantially circular in shape. However, the disclosure is not solimited. The robot cleaner 1 may be any shape (e.g., rectangular,square, or other polygonal or geometric shapes). As shown in FIG. 3, thesensor window 11 may generally conform to the shape of the robot cleaner1 and be mounted to the front of the body 20. The sensor window 11 maypartially extend about the perimeter of the robot cleaner 1 for example.That is, as shown in FIG. 3, the sensor window 11 may have asemi-circular shape and partially extend around the robot cleaner in acircumferential manner.

The body 20 may be provided with a printed circuit board (PCB) circuit21 to receive information relevant to operation of the robot cleaner 1and transmit information to cause the robot cleaner 1 to perform aspecific operation. The PCB circuit 21 may be seated on the upperportion of the body 20. The upper surface of the PCB circuit 21 may becovered by the cover 10.

Hereinafter, the configuration or construction of the sensor module 30according to an example embodiment of the present invention will bedescribed in detail.

FIG. 4 is an exploded perspective view showing the sensor module of FIG.3.

Referring to FIG. 4, the sensor module 30 may include a base frame 31,an upper frame 32, and a sensor assembly. The sensor assembly mayinclude a light emitting device 310, a light receiving reflector 34, anda light receiving unit camera 311. The light emitting device 310, thelight receiving reflector 34 and the light receiving unit camera 311 maybe mounted to the base frame 31 or the upper frame 32, and the baseframe 31 and the upper frame 32 may be coupled to each other by afastening member. For example, the fastening member may include one ormore of a screw, bolt, glue, solder, and the like, however thedisclosure is not so limited and may include other types of fasteningmembers as would be understood by those of skill in the art. The sensormodule 30 may be fabricated as one module. Accordingly, ease of assemblyof the robot cleaner 1 may be enhanced by an integrally formed sensormodule 30.

The light emitting device 310 and the light receiving unit camera 311may be mounted to the base frame 31. A plurality of the light emittingdevices 310 may be provided. In FIG. 4, four light emitting devices 310are shown. However, the disclosure is not so limited. The robot cleaner1 may include one, two, three, or more than four light emitting devices310, as desired. The plurality of the light emitting devices 310 may bedisposed at regular or irregular intervals. For example, the lightreceiving unit camera 311 may be arranged at a position corresponding tothe light receiving reflector 34 mounted to the upper frame 32. As shownin FIG. 4, the base frame 31 and upper frame 32 may generally conform tothe shape of the robot cleaner 1 and be mounted to the front of the body20. The base frame 31 and upper frame 32 may partially extend about theperimeter of the robot cleaner 1 for example. That is, as shown in FIG.4, the base frame 31 and upper frame 32 may have a semi-circular shapeand partially extend around the robot cleaner in a circumferentialmanner. Likewise, the light emitting device 310, the light receivingreflector 34 and the light receiving unit camera 311 may be mounted tothe base frame 31 or the upper frame 32 at constant or irregularintervals, in a circumferential or arc-like manner.

The plurality of light emitting devices 310 may be mounted to the baseframe 31. For example, the light emitting device 310 may be an infraredlight emitting diode to emit infrared light. A wide angle lens 312 toconvert light emitted from the light emitting device 310 into a linelight may be mounted to the front of the light emitting device 310. Thewide angle lens 312 may widen the field of view of the light emittingdevice 310. That is, the light emitted from the light emitting device310 may be allowed to emit through a wider angle of emission by the wideangle lens 312, and therefore a wider area may be covered by lightemitted from one light emitting device 310 to sense an obstacle.Thereby, even when the light emitting devices 310 are disposed atconstant intervals, a blind spot having an obstacle that is positionedin front of the robot cleaner 1 but is not sensed may be avoided. Alenticular lens to collect line lights may be further provided at oneside of the light emitting device 310 or the wide angle lens 312. Ifprovided, the wide angle lens 312 may be provided at some or all of thelight emitting devices 310.

A remote control signal reception portion 313 may be mounted to one sideof the base frame 31. The remote control signal reception portion 313may receive a signal from a remote control and then transmit the signalto the controller. Then, the controller may cause the robot cleaner 1 toperform an operation corresponding to the signal.

A plurality of slits 321 may be formed at one side of the front of theupper frame 32. The light emitting devices 310 may be provided atpositions corresponding to the slits 321. The light emitting devices 310may be arranged at the back or inner side of the slits 321, and thelight emitted from the light emitting devices 310 may be transmittedforward from the robot cleaner 1 through the slits 321.

The slits 321 serve to collect light emitted from the light emittingdevices 310 such that the light is transmitted forward from the robotcleaner 1. In addition, the upper sides of the light emitting devices310 may be covered by the slits 321 such that light is shielded. As theupper sides of the light emitting devices 310 are shielded, the lightemitted from the light emitting devices 310 may be prevented from beingreflected from the inner surface of the sensor window 11 and from beingincident on the light receiving reflectors 340 positioned at the upperportions of the light emitting devices 310. Thereby, the erroneoussensing of the presence of an obstacle that is not actually in front ofthe robot cleaner 1 may be prevented.

The upper frame 32 may be provided with a mount 330 protruding upwardfrom the upper frame 32. The mount 330 may be integrally formed with theupper frame 32 through injection molding, or may be separatelyfabricated and mounted to the upper frame 32. A seating portion 332allowing the light receiving reflector 340 to be mounted thereto may beprovided at the upper side of the mount 330. A hole 331 penetrated bythe light receiving reflector 340 may be formed in the seating portion332.

A lens frame 341 may be mounted to the light receiving reflector 340.The lens frame 341 may be seated on the seating portion 332. At thistime, the light receiving reflector 340 may protrude downward from theseating portion 332 through the hole 331. Thereby, the upper frame 32may be mounted such that the light receiving reflector 340 is exposed.For example, as shown in FIG. 4 and FIG. 5, a bottom portion of thelight receiving reflector 340 may be disposed below the seating portion332 of mount 330, such that light which reflects off an object orobstacle T and passes through sensor window 11, may be incident to anexposed portion of the light receiving reflector 340.

The upper frame 32 positioned at the lower portion of the lightreceiving reflector 340 may be provided with a hole 320. The lightreceiving unit camera 311 may be provided at the lower portion or innerside of the hole 320. When reflected light is incident on the lightreceiving reflector 340, the light receiving unit camera 311 may receiveinformation about the reflected light incident on the light receivingreflector 340 and transmit the information to the controller.

The light receiving reflector 340 may be formed in a conical shape, asshown in FIG. 5, for example. Accordingly, when the light receivingreflector 340 is mounted to the upper frame 32 with the lens frame 341seated on the seating portion 332, the light receiving reflector 340 maybe arranged such that the bottom surface thereof faces upward and thevertex thereof faces downward. A lenticular lens may be further providedto the light receiving reflector 340 or the light receiving unit camera311 to increase resolution of the reception portion.

A docking sensor 37 may be mounted to the mount 330. The docking sensor37 may transmit a signal to a signal reception portion provided to or by(e.g., at) the docking station (not shown) of the robot cleaner 1. Forexample, when dust collected in the robot cleaner 1 needs to be removedor the robot cleaner 1 needs to be charged, the location of the robotcleaner 1 may be sensed by the docking sensor 37, and then the robotcleaner 1 may be guided to the docking station.

A turret 36 may be mounted to the mount 330. The turret 36 may include asensor mounting portion 360 and an upper cover 361. The sensor mountingportion 360 may be mounted to the mount 330. A hole 362 allowing thedocking sensor 37 to be inserted thereinto may be formed in the sensormounting portion 360. The docking sensor 37 may be inserted into thehole 362 and fixed. The upper cover 361 may be mounted to cover theupper portion of the sensor mounting portion 360 such that the dockingsensor 37 is not exposed, for example, to the external environment.

When the sensor mounting portion 360 is positioned at the upper side ofthe light receiving reflector 34, a bracket 35 may be interposed betweenthe light receiving reflector 34 and the docking sensor 37 to space thelight receiving reflector 340 and the docking sensor 37 apart from eachother. A protruding rib 350 may be provided to the bracket 35. Thebracket 35 may be mounted to the mount 330 or the seating portion 332and positioned between the light receiving reflector 34 and the dockingsensor 37 with the light receiving reflector 34 and the docking sensor37 spaced apart from each other by the protruding rib 350.

In the structure as disclosed above, the sensor module 30 may includethe sensor assembly, the remote control signal reception portion 313,and the docking sensor 37, and two or more of these components may bemodularized (or integrally formed) as one unit. Thereby, the efficiencyof assembly of the robot cleaner 1 may be improved.

FIG. 5 is a view schematically illustrating sensing of an obstacle bythe sensor module of FIG. 3.

Referring to FIG. 5, light emitted from the light emitting device 310 ofthe sensor module 30 may be reflected from the surface P of an obstacleT positioned in front of the robot cleaner 1 and incident on the pointP′ of the light receiving reflector 340. The image of the light incidenton the light receiving reflector 340 may be input to the light receivingunit camera 311 positioned on the lower portion of the light receivingreflector 340. Then, the light receiving unit camera 311 may transmitinformation about the image of the light incident on the light receivingreflector 340 to the controller (not shown). Thereby, the presence ofthe obstacle T in front of the robot cleaner 1 may be sensed.

Meanwhile, light emitted from the light emitting device 310 may bereflected from the inner surface f of the sensor window 11. The lightreflected from the inner surface f of the sensor window 11 may beprevented from being incident upon the light receiving reflector 340, bythe inner surface of the upper portion of the upper frame 32 forming theslits 321. Thereby, the light reflected from the inner surface f of thesensor window 11 is prevented from causing an erroneous sensing of thepresence of an obstacle.

In the example embodiments disclosed herein, the light receivingreflector 340 may be arranged on the mount 330 protruding upward fromthe upper frame 32, and the light receiving unit camera 311 may bearranged at the lower portion of the light receiving reflector 340.Light emitted from the light emitting device 310 may be reflected andincident upon the light receiving reflector 340, and the informationabout the image of the light incident on the light receiving reflector340 may be transmitted to the controller (not shown).

Alternatively, the light receiving unit camera 311 may be arranged ordisposed on the mount 330 protruding upward from the upper frame 32 suchthat light emitted from the light emitting device 310 is reflected anddirectly incident on the light receiving unit camera 311. In this case,light emitted from the light emitting device 310 may be reflected andincident upon the light receiving unit camera 311, and then the lightreceiving unit camera 311 may transmit the information about the imageof the incident light to the controller (not shown).

In this case, light emitted from the light emitting device 310 may betransmitted forward from the robot cleaner 1 through the slits 321, andthe upper side of the light emitting device 310 may be shielded againstthe light. As the upper side of the light emitting device 310 isshielded, light emitted from the light emitting device 310 may beprevented from being reflected from the inner surface of the sensorwindow 11 and incident upon the light receiving unit camera 311positioned on the upper portion of the light emitting device 310.Thereby, the light from the light emitting devices 310 may betransmitted forward from the robot cleaner 1 through the slits 321 inthe form of a line light, and erroneous sensing of the presence of anobstacle that is not in front of the robot cleaner 1 may be prevented.

FIG. 6 is a view partially showing a sensor module according to anembodiment of the present invention, FIG. 7 is a cross-sectional viewshowing the sensor module of FIG. 6, and FIG. 8 is a view schematicallyillustrating sensing of an obstacle by the sensor module of FIG. 6.

Referring to FIGS. 6 and 7, a step portion 322 may be formed at theupper frame 32 of a sensor module 30 of the illustrated embodiment. Thestep portion 322 may be formed on the front upper surface of the upperframe 32. Specifically, the step portion 322 may be formed on the uppersurface of the upper frame 320 forming the slits 321. As the stepportion 322 is formed, light reflected from an obstacle close to therobot cleaner 1 may be prevented from being intercepted by the uppersurface of the upper frame 32 forming the slits 321 failing to beincident upon the light receiving reflector 340.

Referring to FIG. 8, when there is an object or obstacle T positionedclosed to the robot cleaner 1, light from the light emitting device 310may be emitted onto the obstacle T. The light reflected from the surfaceR of the obstacle T may be received at the point R′ of the lightreceiving reflector 340. As shown in FIG. 8, the path of the lightreflected from the surface R of the obstacle T is not obstructed by theupper surface of the upper frame 32 forming the slits 321 since the stepportion 322 is formed on the front upper surface of the upper frame 32.Thereby, the obstacle T positioned close to the robot cleaner 1 may beaccurately sensed even though the upper frame 32 protrudes forward overthe mounting position of the light emitting device 310. That is, stepportion 322 may extend from the upper frame 32 at an downward incline orangle toward the sensor window 11. By way of comparison, the exampleembodiment of FIG. 5 does not include the step portion 322, and theupper frame 32 may extend above the light emitting device 310 toward thesensor window 11.

As the distance between the obstacle T and the robot cleaner 1decreases, the distance from the vertex of the light receiving reflector340 to the point upon which the light reflected from the obstacle T isincident may also decrease. Referring to FIGS. 5 and 8, the distance L1between the obstacle T and the robot cleaner 1 shown in FIG. 5 isgreater than the distance L2 between the obstacle T and the robotcleaner 1 shown in FIG. 8. The light reflected from the obstacle T shownin FIG. 5 may be incident upon the point P′ of the light receivingreflector 340. The distance from the vertex A of the light receivingreflector 340 to the point P′ may be defined as D1. The light reflectedfrom the obstacle T shown in FIG. 8 may be incident upon the point R′ ofthe light receiving reflector 340. The distance from the vertex A of thelight receiving reflector 340 to the point R′ may be defined as D2.Herein, D1 is greater than D2. That is, a relationship may beestablished or perceived that as the distance between the robot cleaner1 and an obstacle T increases, the distance between the vertex A of thelight receiving reflector 340 and the point of incidence upon the lightreceiving reflector 340 increases. Therefore, the distance from therobot cleaner 1 to the obstacle T may be measured according to thedistance from the vertex A of the light receiving reflector 340 to thepoint upon which the light reflected from the obstacle T is incident.The light receiving unit camera 311 may transmit information about thelight incident upon the light receiving reflector 340 to the controller,and then the controller may measure the location of the obstacle T usingthe information on the position on which the light is incident, andadjust the direction of movement of the robot cleaner 1.

FIG. 9 is a view showing a sensor module according to another embodimentof the present invention.

Referring to FIG. 9, the sensor module 30 of the illustrated embodimentmay include a base frame 31, a light shield panel 38 and a sensor window11. The base frame 31 may be coupled to the light shield panel 38, andthe sensor window 11 may be coupled to the base frame 31 or the lightshield panel 38.

Similar to the sensor module 30 of the previous example embodiment, thelight emitting device 310 and the light receiving unit camera 311 may bemounted to the base frame 31, and the light receiving reflector 34 andthe docking sensor 37 may be mounted to the light shield panel 38.

The light shield panel 38 may be positioned at the upper portion of thelight emitting device 310 mounted to the base frame 31. The light shieldpanel 38 may prevent the light emitted from the light emitting device310 from being reflected from the inner surface of the sensor window 11and incident upon the light receiving reflector 340. Thereby, anerroneous sensing of the presence of an obstacle that is not in front ofthe robot cleaner 1 may be prevented. Meanwhile, a step portion may beformed on the front upper surface of the light shield panel 38, similarto the step portion 322 formed at the upper frame 32 in the previousexample embodiment. Thereby, an obstacle close to the robot cleaner 1may be accurately sensed.

The sensor window 11 may be modularized. That is, the sensor module 30may include the sensor window 11. Accordingly, in assembling the robotcleaner 1, the sensor window 11 does not need to be separatelyconnected. Therefore, the efficiency of assembly of the robot cleaner 1may be enhanced.

The sensor window 11 may be integrated with the light shield panel 38.That is, the sensor module 30 and the light shield panel 38 may beintegrated and provided to the robot cleaner 1 as one unit. As thesensor module 30 and the light shield panel 38 are integrated to beprovided to the robot cleaner 1, the efficiency of assembly of the robotcleaner 1 may be enhanced.

The slits 321 of the upper frame 32 or the light shield panel 38provided to prevent light emitted from the light emitting device 310from being reflected from the inner surface of the sensor window 11 andincident upon the light receiving reflector 340 may be defined orreferred to as a light shielding portion.

As a modularized sensor to sense an obstacle is mounted to the robotcleaner 1, the efficiency of assembly of the robot cleaner 1 may beenhanced. In addition, as the sensor module is provided with a lightshielding portion, the light emitted from a light emitting device may beprevented from being reflected from the inner side of the sensor windowand incident upon a light receiving reflector, thereby preventing anerroneous sensing of an obstacle. When a step portion is formed on thefront upper portion of the light shielding portion, an obstaclepositioned closer to the robot cleaner may also be more accuratelysensed. That is, the step portion enables an object to be sensed by therobot cleaner at a closer distance relative to an embodiment of therobot cleaner which does not include the step portion. Because the robotcleaner is able to sense an object at a closer distance, the robotcleaner may be operated more closely to objects without contacting theobject, allowing the robot cleaner to perform a more thorough job ofcleaning while maintaining separation from the object.

As is apparent from the above description, a sensor module and robotcleaner according to the example embodiments disclose herein may preventerroneous sensing when an obstacle is not actually present in front ofthe robot cleaner, ensuring that the sensor accurately senses obstacles.In addition, as the sensor to be mounted to the robot cleaner ismodularized, the efficiency of assembly of the robot cleaner may beenhanced.

The robot cleaner according to the above-described example embodimentsmay use one or more processors. For example, the controller of the robotcleaner may be embodied as a processing device and may be implementedusing one or more general-purpose or special purpose computers, such as,for example, a processor, a central processing unit (CPU), a graphicsprocessing unit (GPU), a digital signal processor (DSP), amicrocomputer, a field programmable array, a programmable logic unit, anapplication-specific integrated circuit (ASIC), a microprocessor or anyother device capable of responding to and executing instructions oroperations in a defined manner.

Although example embodiments of the present invention have been shownand described, it would be appreciated by those skilled in the art thatchanges may be made to these embodiments without departing from theprinciples and spirit of the invention, the scope of which is defined inthe claims and their equivalents.

What is claimed is:
 1. A robot cleaner comprising: a body including acleaning unit to perform a cleaning operation; a cover to cover an upperportion of the body; a sensor module mounted to the body to sense anobstacle; and a sensor window provided at one side of the sensor module,wherein the sensor module comprises: a light emitting device to emitlight through the sensor window; a light receiving reflector on whichlight emitted from the light emitting device and reflected from theobstacle is incident; and a light shielding portion interposed betweenthe light emitting device and the light receiving reflector to block thelight emitted from the light emitting device from being reflected froman inner surface of the sensor window and incident upon the lightreceiving reflector.
 2. The robot cleaner according to claim 1, whereinthe sensor module comprises a base frame and an upper frame coupled tothe base frame.
 3. The robot cleaner according to claim 2, wherein aslit is formed at one side of a front of the upper frame, and the lightshielding portion includes an upper surface of the upper frame formingthe slit.
 4. The robot cleaner according to claim 3, wherein the lightemitting device is mounted to the base frame to correspond to a positionof the slit, and the light emitted from the light emitting deviceradiates forward through the slit.
 5. The robot cleaner according toclaim 3, wherein a step portion is formed on a front upper surface ofthe upper frame.
 6. The robot cleaner according to claim 2, wherein thelight receiving reflector is mounted to the upper frame.
 7. The robotcleaner according to claim 6, wherein the upper frame is provided with amount protruding upward, and the light receiving reflector is mounted toan upper side of the mount.
 8. The robot cleaner according to claim 7,wherein the upper frame is provided with a hole at a positioncorresponding to a lower portion of the mount.
 9. The robot cleaneraccording to claim 8, wherein the base frame is provided with a lightreceiving unit camera to receive information about the reflected lightincident upon the light receiving reflector, the light receiving unitcamera arranged to face the light receiving reflector.
 10. The robotcleaner according to claim 7, wherein a docking sensor to communicatewith the docking station is mounted to the mount.
 11. The robot cleaneraccording to claim 10, wherein the docking sensor is positioned abovethe light receiving reflector.
 12. The robot cleaner according to claim11, wherein a bracket to space the docking sensor from the lightreceiving reflector is interposed between the docking sensor and thelight receiving reflector.
 13. The robot cleaner according to claim 2,wherein the base frame is provided with a remote control signalreception portion to receive a signal from a remote control.
 14. Therobot cleaner according to claim 2, wherein, the sensor module ismodularized as one unit by mounting the light emitting device to thebase frame, mounting the light receiving reflector to the upper frame,and coupling the base frame to the upper frame, and the sensor module ismounted to a front of the body.
 15. The robot cleaner according to claim1, wherein the sensor window is integrated with the sensor module.
 16. Asensor module comprising: a base frame; a plurality of light emittingdevices mounted to the base frame; a light shielding portion positionedabove the light emitting devices; a light receiving reflector providedabove the light shielding portion; and a light receiving unit cameramounted to the base frame to receive an image relevant to light incidentupon the light receiving reflector, wherein the base frame, the lightemitting devices, the light shielding portion, the light receivingreflector, and the light receiving unit camera are integrated with eachother.
 17. The sensor module according to claim 16, wherein a slit isformed at one side of the light shielding portion, and a correspondingone of the light emitting devices is provided at a positioncorresponding to the slit, such that light emitted from the lightemitting device is radiated through the slit.
 18. The sensor moduleaccording to claim 16, further comprising a sensor window coupled to thebase frame or the light shielding portion.
 19. The sensor moduleaccording to claim 18, wherein the base frame, the light shieldingportion and the sensor window are integrated with each other.
 20. Thesensor module according to claim 16, wherein a step portion is formed ona front upper surface of the light shielding portion.
 21. A sensormodule comprising: a base frame; a light emitting device mounted to thebase frame to emit light through a sensor window toward an object; alight receiving unit camera to receive light emitted from the lightemitting device and reflected from the obstacle; and a light shieldingportion positioned above the light emitting device to prevent lightemitted from the light emitting device and reflected from an innersurface of the sensor window from being received by the light receivingcamera.
 22. The sensor module according to claim 21, further comprisinga light receiving reflector to receive light emitted from the lightemitting device and reflected from the obstacle, and to reflect thelight emitted from the light emitting device and reflected from theobstacle to the light receiving unit camera.
 23. The sensor moduleaccording to claim 21, wherein the light shielding portion includes anupper frame disposed above the base frame and the light emitting device,and a bottom surface of the upper frame prevents light emitted from thelight emitting device and reflected from the inner surface of the sensorwindow from being received by the light receiving camera.
 24. The sensormodule according to claim 23, further comprising a mount disposed on anupper surface of the upper frame, wherein the light receiving unitcamera is arranged on the mount to receive light emitted from the lightemitting device and reflected from the obstacle directly.
 25. The sensormodule according to claim 23, wherein an end portion of the upper frameadjacent to the inner surface of the sensor window steps down at anincline toward the inner surface of the sensor window.